Panel system for building studs

ABSTRACT

A panel system is provided for constructing building walls. The panel system includes panels with first and second tabs adapted for installation on building studs, including metal building studs. The panels may be made from a plastic material that is recyclable, thereby minimizing the environmental impact of building construction. The panels also include overlapping edges to provide a smooth joint between adjacent panels.

BACKGROUND

[0001] The present invention relates generally to building walls, and more particularly to panels attached to building studs.

[0002] As those skilled in the building construction arts well know, wall surfaces have traditionally been constructed with sheetrock, which is fastened with screws or nails to equally-spaced vertical studs. Vertical building studs form the framing of walls and the like in a building and provide support for the ceiling. In the past, the building studs were usually made from wood. However, due to the increasing cost and difficulty of obtaining high quality wood, the use of metal studs in place of wood studs has become more common in building construction. This trend has seen wide acceptance in the construction of commercial buildings, where most new construction of commercial buildings now uses metal studs. By contrast, home construction has been slower to adopt the use of metal studs in place of wood studs. As a result, construction of residential homes still commonly uses traditional wood studs. However, because of the problems associated with wood studs as compared to the relative benefits of metal studs, even the home construction market is moving to adopt the use of metal studs in place of wood studs.

[0003] Despite the movement towards more cost effective and reliable materials for the building studs, both commercial and home construction still primarily uses sheetrock to form the outer surfaces of the walls. Although sheetrock has been used for many years in building construction, there are a number of disadvantages associated with its use.

[0004] One problem associated with the use of sheetrock is the waste that is generated during construction and demolition. As those in the art know, sheetrock is manufactured and sold in standardized sizes. During construction, sheets of sheetrock are cut to the particular sizes needed at the construction site. As a result, a significant amount of leftover sheetrock is generated at the construction site after the sheetrock is cut to size. This leftover sheetrock ends up being discarded and must be disposed. In addition, since sheetrock is relatively fragile, further waste is commonly generated at the construction site due to inadvertent damage to the sheets of sheetrock. During demolition of a building, all of the sheetrock in the building is completely wasted. Since there is no established system for recycling sheetrock, wasted sheetrock has become a significant environmental problem. Despite the fact that sheetrock is not thought to be a hazardous material, the sheer magnitude of sheetrock waste creates considerable disposal problems. Normally, sheetrock waste is disposed of in landfills. However, due to the increasing cost and social disapproval of ever-expanding landfills, solutions are needed to minimize the amount of waste generated by building construction and demolition.

[0005] Another problem associated with the use of sheetrock is the amount of labor that is needed at the construction site to install sheetrock. As those in the art know, installing sheetrock as the wall surfaces of a building requires numerous, time-consuming steps. This is so much so that building contractors often hire specialists who concentrate solely on sheetrock installation. The following steps summarize the process of installing sheetrock and provide an example of the labor and special skills required to install sheetrock. First, sheets of sheetrock must be cut to the particular sizes needed for a particular job. The sheetrock sections are then fastened to the building studs with screws or nails. Next, all of the joints between the sheetrock sections are covered up with tape. Special cement is then used to cover up the tape. After the cement dries, the cement is sanded to provide a smooth surface over the entire wall surface. Finally, the wall surface is finished by painting and/or texturing. The combination of steps required to install sheetrock results in an expensive and time-consuming process.

[0006] Additional problems are associated with the fact that most of the work related to sheetrock installation must be performed at the construction site. One problem is the higher cost associated with construction site work compared to mass production operations at a factory. One reason for this higher cost is that construction workers must constantly move from site to site, moving their equipment each time and having to refamiliarize themselves with each new location. Likewise, efficiency techniques that are possible with high-scale automation cannot be readily adapted to work at a construction site. In addition, having to hire specialists with expertise in installing sheetrock can raise construction costs even further. Another problem is related to the fact that the overall length of time that it takes to complete a building is proportional to the amount of labor needed at the construction site. Typically, building owners wish that construction will proceed quickly and finish in as short a time as possible. However, because of the significant amount of work that is required to install sheetrock, construction is slowed and the final completion of construction is delayed.

[0007] Another problem associated with sheetrock is the permanent nature of sheetrock. Once sheetrock has been installed as the wall surfaces in a building, there is no easy way to remove the sheetrock from the building studs. The only way to remove sheetrock once it has been installed is to destroy the sheetrock and tear it away from the building studs. This however is inconvenient and expensive. Situations in which a building owner might wish to temporarily remove a sheetrock wall surface include examples such as maintenance to the wiring behind a wall (like adding new communication wiring), maintenance on the building studs, and/or adding or changing insulation. Moreover, since sheetrock is permanently fastened to the building studs, the outer wall surface cannot be relocated to different walls if office workers move to a different part of a building or a homeowner moves to a new house.

BRIEF SUMMARY

[0008] Accordingly, a panel system is provided with panels adapted for easy installation on building studs. The panels provide a first tab and a second tab for fastening to the building studs. The panel may be made from extruded plastic to allow recycling of the panels and lower costs. In addition, the panels may be used with metal building studs. The panel also provides overlapping side edges to account for variation in the placement of the building studs.

BRIEF DESCRIPTION OF THE DRAWINGS

[0009] The invention, including its construction and method of operation, is illustrated diagrammatically in the drawings, in which:

[0010]FIG. 1 is a perspective view of a wall with panels fastened to building studs;

[0011]FIG. 2 is a front elevational view of a wall with panels fastened to building studs;

[0012]FIG. 3 is a cross-sectional view of a wall with panels fastened to metal building studs;

[0013]FIG. 4 is a cross-sectional view of a second tab of the panel;

[0014]FIG. 5 is a cross-sectional view of an end panel.

DETAILED DESCRIPTION

[0015] Referring now to the drawings, a panel system 10 is provided for the wall surfaces of buildings. The panel system 10 is designed to replace sheetrock wall surfaces and eliminate many of the problems associated with sheetrock. Accordingly, the panel system 10 includes a series of panels 30 that may be fastened to equally-spaced vertical building studs 12. In the preferred embodiment, the panels 30 are specifically designed to be fastened to industry standard metal studs 12. Although various materials may be used for the panels 30, plastic is preferred since it is flexible, can be formed with integral features, and is recyclable. In the described embodiment, the integral features of the panels 30 are designed to allow the panels 30 to be formed by a plastic extrusion process.

[0016] The first side 32 of the panels 30 includes a first tab 34 that is shaped complementary to the open side 14 of a metal stud 12. Metal studs 12 are usually formed from bended sheet steel. Thus, a metal stud 12 typically has an open side 14 with opposing ends 16 extending a short distance in from the outer mounting faces 18 of the stud 12. Normally, the metal stud 12 has a closed side 20 with a closed face 22 on the opposite side of the metal stud 12. Accordingly, the first tab 34 has a first section 36 that extends inward from the inside surface 31 of the panels 30 and extends along the outer face 17 of one of the metal stud opposing ends 16. A second section 38, attached at the inside end of the first section 36, extends inside of the metal stud 12 along the end 19 of the opposing end 16.

[0017] The second side 40 of the panels 30 includes a second tab 42 that is shaped to grip the closed face 22 of the closed side 20 of the metal stud 12. The second tab 42 extends inward along the closed face 22 and is angled approximately 3° to 12° towards the closed face 22. In the described embodiment, teeth 44 are formed in the second tab 42 along the side adjacent the closed face 22.

[0018] The first and second sides 32, 40 of the panels 30 also include cooperating edges 46, 52 which form the vertical joint between adjacent panels 30. The first side edge 46 extends along the outer mounting face 18 of the metal stud 12. The outer surface 48 of the first side edge 46 is angled inward so that a terminus 50 of the first side edge 46 is formed adjacent the outer mounting face 18 of the metal stud 12. The second side edge 52 extends along a short distance of the outer mounting face 18 of the metal stud 12 and then extends outward away from the outer mounting face 18. The outer surface 54 of the second side edge 52 extends generally parallel to the outer surface 33 of the panels 30 thus forming a terminus 56 that abuts the outer surface 48 of the first side edge 46.

[0019] A variety of other features may also be provided with the panels 30 either by extruding those features into the panels 30, stamping or molding the features, or cutting features in. For example, in the described embodiment integrated lights 58 may be provided with the panels 30. The light openings 60 are formed by stretching sections 62 of the panel 30 away from the wall surface 33. Light switches 64, outlets 66 and communication ports 68 may also be provided by cutting openings in the panels 30. Typically, these openings will be cut at the construction site as needed.

[0020] The end panel 70 is also preferably formed from a plastic material and may also be extruded. The end panel 70 includes a first section 72 that extends along either the closed side 20 or the open side 14 of the metal stud 12. The end panel 70 also includes a second section 74 along each side of the first section 72. The second sections 74 extend outward from the first section 72 and extend along the outer mounting faces 18 of the metal studs 12. In order to ensure a tight fit with the metal stud 12, the second sections 74 are formed with an inward facing draft angle. The edges 76 of the second sections 74 are shaped like the first side edges 46 and second side edges 52 described above to cooperate in a like manner with the side edges 46, 52 of the adjacent 30 panels. (In FIG. 5, the second sections 74 of the end panel 70 are shown with edges 76 like that of the first side edge 46 of the panels 30 but could also be shaped like the second side edge 52 of the panels 30 where needed). Adhesive 78 (i.e., adhesive tape or glue) is also provided along the inside surface 80 of the first section 72 of the end panel 70.

[0021] Base panels 90 and ceiling trim 92 may also be provided with the panel system 10. The base panels 90 and ceiling trim 92 may be glued or otherwise fastened to the panels 30. Although the base panels 90 and ceiling trim 92 are preferably made from plastic materials like the panels 30 and end panels 70, other more traditional materials may also be used.

[0022] It is now apparent that the panel system 10 provides numerous advantages over conventional sheetrock. One problem that is solved with the panel system 10 compared to the use of sheetrock is waste. Typically, the panels 30 will be formed to the necessary length when they are manufactured. Thus, when the panels 30 are installed at the construction site, waste will be minimized since the panels 30 will not need to be cut to size. More importantly, the panels 30 can be made out of plastic that is recyclable. Thus, to the extent that some cutting and waste still occurs at the construction site, the discarded panel sections can be disposed of at a recycling facility to avoid the environmental problems associated with disposing waste in landfills. In addition, the panels 30 may be manufactured from plastic materials that have already been recycled from previous uses, thereby further addressing environmental concerns. The plastic panels 30 may also be recycled at the time of demolition by recovering the panels 30 (and end panels 70, base panels 90 and ceiling trim 92) and sending them to a recycling facility instead of disposing of the old building material in a landfill.

[0023] The design of the panels 30 also reduces the labor costs of constructing the wall surfaces of a building. As previously described, sheetrock installation is a time-consuming process that requires numerous steps. By contrast, the panels 30 will be easier to install and will require less labor. The panels 30 may be installed by sliding the first side 32 of a panel 30 into the open side 14 of a metal stud 12 so that the first tab 34 fits onto one of the opposing ends 16 of the metal stud 12. The second side 40 of the panel 30 is then pressed inward so that the second tab 42 grips against the closed face 22 of the metal stud 12. The angle of the second tab 42 allows the second tab 42 to flex and provide sufficient grip to retain the panel 30 in place. In addition, the second tab 42 provides a sufficient range of flexure to accommodate variations in stud 12 placement. The joint between adjacent panels 30 provides a smooth and aesthetically acceptable appearance due to the overlapping first and second side edges 46, 52. The overlapping first and second side edges 46, 52 avoid inconsistent gaps that would occur if straight abutting edges were used due to variations in stud 12 placements. In most cases, no screws or other fasteners will be needed to attach the panels 30 to the building studs 12. The process is repeated for each of the panels 30. The end panels 70 are installed by sliding the second sections 74 over the outer mounting faces 18 of the metal studs 12 until the inside surface 80 of the first section 72 abuts the closed side 20 or open side 14 of the metal stud 12. The adhesive 78 (i.e., adhesive tape or glue) retains the end panel 70 in place. The base panels 90 and ceiling trim 92 are then installed using glue or other fasteners.

[0024] As will be appreciated, the panels 30 can be installed quicker and easier than traditional sheetrock. This will save significant costs in building construction by reducing the amount of labor that is needed at a construction site. Moreover, the installation of the panels 30 is relatively simple, thereby eliminating the need for specialists. In most cases the panels 30 will not require any finishing operations beyond basic installation, since the outer panel surfaces 33 can be textured during the manufacturing operation with a variety of textures and any choice of colors for the plastic may be used. The speed and ease with which the panels 30 can be installed also decreases the overall time needed to complete construction. Thus, building owners will be able to occupy a new building sooner after construction starts than is possible with the use of sheetrock.

[0025] Another benefit of the panel system 10 is that the panels 30 can be removed relatively easily. This will be helpful in a number of situations. For example, it is not uncommon for mistakes to be made during construction which require the wall surfaces to be removed to correct problems with the walls. With the panel system 10, the panels 30 can simply be pulled out and temporarily removed and later replaced instead of having to tear apart permanent sheetrock as is now done. In addition, the panels 30 permit more frequent and significant repair work to be done to the walls during regular use of the building. For example, the panels 30 could be temporarily removed and later replaced in order to work on wires in the wall, work on the studs 12, or install insulation. Furthermore, since the panels 30 are removeable, building owners may choose to relocate the panels 30 to different building locations when workers are relocated to different areas or when a home owner sells a house and buys a new one.

[0026] While a preferred embodiment of the invention has been described, it should be understood that the invention is not so limited, and modifications may be made without departing from the invention. The scope of the invention is defined by the appended claims, and all devices that come within the meaning of the claims, either literally or by equivalence, are intended to be embraced therein. 

We claim:
 1. A panel adapted for installation on building studs, comprising: a first side comprising a first tab and a first side edge, said first tab being adapted for fastening to a first building stud, said first side edge being adapted to be adjacent a side edge of a first adjacent panel; and a second side comprising a second tab and a second side edge, said second tab being adapted for fastening to a second building stud, said second side edge being adapted to be adjacent a side edge of a second adjacent panel.
 2. The panel according to claim 1, wherein said panel is made from a plastic material.
 3. The panel according to claim 2, wherein said panel is extruded.
 4. The panel according to claim 1, wherein said first and second building studs are made from metal.
 5. The panel according to claim 4, wherein said first tab is shaped complementary to an open side of said first metal building stud.
 6. The panel according to claim 5, wherein said open side of said first metal building stud comprises an opposing end comprising an outer face and an end, and wherein said first tab comprises a first section extending along said outer face and a second section extending along said end.
 7. The panel according to claim 1, wherein said second tab is flexible and is angled towards a closed face of said second building stud thereby being adapted to grip said closed face.
 8. The panel according to claim 7, wherein said second tab is angled about 3° to 12° and comprises teeth adapted to grip said closed face of said second building stud.
 9. The panel according to claim 1, wherein said first side edge is overlapped by said side edge of said first adjacent panel.
 10. The panel according to claim 9, wherein said first side edge extends along an outer mounting face of said first building stud and is angled inward forming a terminus adjacent said outer mounting face.
 11. The panel according to claim 1, wherein said second side edge overlaps said side edge of said second adjacent panel.
 12. The panel according to claim 11, wherein said second side edge extends along an outer mounting face of said second building stud and is angled outward forming a terminus abutting an outer surface of said side edge of said second adjacent panel.
 13. The panel according to claim 1, further comprising a light integrally formed on said panel.
 14. The panel according to claim 13, wherein said light is formed with sections of said panel stretched away from an outside surface of said panel.
 15. The panel according to claim 1, wherein said panel is made from a plastic material; wherein said first and second building studs are made from metal; wherein said first tab is shaped complementary to an open side of said first metal building stud; and wherein said second tab is flexible and is angled towards a closed face of said second metal building stud thereby being adapted to grip said closed face.
 16. The panel according to claim 15, wherein said panel is extruded; wherein said open side of said first metal building stud comprises an opposing end comprising an outer face and an end, and wherein said first tab comprises a first section extending along said outer face and a second section extending along said end; and wherein said second tab is angled about 3° to 12° and comprises teeth adapted to grip said closed face of said second metal building stud.
 17. The panel according to claim 16, wherein said second side edge overlaps said side edge of said second adjacent panel; and wherein said second side edge extends along an outer mounting face of said second metal building stud and is angled outward forming a terminus abutting an outer surface of said side edge of said second adjacent panel.
 18. A panel system adapted for installation on building studs, comprising: a panel and an end panel; said panel comprising a first side comprising a first tab and a first side edge, said first tab being adapted for fastening to a first building stud, said first side edge being adapted to be adjacent a side edge of a first adjacent panel, and a second side comprising a second tab and a second side edge, said second tab being adapted for fastening to a second building stud, said second side edge being adapted to be adjacent a side edge of said end panel; said end panel comprising a first section extending along a side of an end building stud and a second section extending along an outer mounting face of said end building stud, said second section comprising said side edge of said end panel.
 19. The panel system according to claim 18, wherein said end panel is fastened to said end building stud with adhesive.
 20. The panel system according to claim 19, further comprising a base panel.
 21. The panel system according to claim 20, further comprising a ceiling trim.
 22. A panel adapted for installation on metal building studs, comprising: a first side comprising a first tab and a first side edge, said first tab being shaped complementary to an open side of a first metal building stud; and a second side comprising a second tab and a second side edge, said second tab being flexible and angled towards a closed face of a second metal building stud thereby being adapted to grip said closed face. 